CN119173169A

CN119173169A - Footwear with external reinforcing fluid-filled bladder

Info

Publication number: CN119173169A
Application number: CN202380025075.2A
Authority: CN
Inventors: Z·M·埃尔德; L·E·弗洛雷斯桑多瓦尔; T·W·米勒; L·D·佩顿
Original assignee: Nike Innovate CV USA
Current assignee: Nike Innovate CV USA
Priority date: 2022-05-11
Filing date: 2023-05-10
Publication date: 2024-12-20
Also published as: EP4521988A1; WO2023220183A1; US20230363495A1; WO2023220184A1; TW202408390A; TWI852548B; EP4521987A1; US20230363494A1; TW202348157A

Abstract

A cushioning structure includes an outer reinforcing bladder having a first polymer sheet and a second polymer sheet, wherein each polymer sheet includes an inner surface and an opposing outer surface. The first reinforcing layer is in contact with the outer surface of the first polymeric sheet, wherein the first reinforcing layer has a greater modulus than the first polymeric sheet. The second reinforcing layer is in contact with the outer surface of the second polymeric sheet, wherein the second reinforcing layer has a greater modulus than the second polymeric sheet. The bladder includes an interior volume and a peripheral flange surrounding the interior volume, and the reinforcement layer is secured to the polymer sheet only at the peripheral flange.

Description

Footwear with external reinforcing fluid-filled bladder

Cross Reference to Related Applications

The present application claims priority from U.S. provisional patent application No.63/340,744 filed 5/11 at 2022 and U.S. provisional patent application No. 63/488,755 filed 3/6 at 2023, the disclosures of both applications and their disclosures are incorporated herein by reference in their entireties.

Technical Field

The present disclosure relates generally to cushioning structures including external reinforcing bladders, including cushioning structures for articles of footwear, apparel, or athletic equipment.

Background

Cushioning structures are commonly used to provide cushioning in a variety of consumer products, including in articles of footwear, apparel, and athletic equipment. Articles of footwear generally include a sole structure configured to be positioned under a foot of a wearer to isolate the foot from the ground. Sole structures in athletic footwear are generally configured to provide cushioning, motion control, and/or resilience.

Drawings

The drawings described herein are for illustration purposes only and are schematic in nature and are intended to be illustrative rather than limiting the scope of the present disclosure.

FIG. 1 is a schematic side view of an article of footwear having a sole structure with a fluid-filled cushioning member extending through a heel region, a midfoot region, and a portion of a forefoot region.

Fig. 2A is a schematic perspective view of an external reinforcing fluid-filled bladder.

FIG. 2B is a schematic cross-sectional view of the external reinforcing fluid-filled bladder of FIG. 2A, taken along line A-A.

Fig. 3 is a schematic top view of an external reinforcing fluid-filled bladder.

FIG. 4 is a schematic partially exploded view of a stacked assembly for forming an external reinforcing fluid-filled bladder using a weld-resistant material to selectively inhibit fusion of layers together.

FIG. 5A is a schematic rear perspective view of an article of footwear including a sole structure with a plurality of discrete fiber-reinforced bladders.

Fig. 5B is a schematic exploded view of the article of footwear of fig. 5A.

Detailed Description

The present disclosure relates generally to an article of footwear having a sole structure with at least one external reinforcing cushioning structure, such as an unfilled bladder or a fluid-filled bladder. As will be discussed below, the present design utilizes an external reinforcing layer to constrain and provide structure to a more interior polymer sheet operable to contain pressurized fluid. The outer reinforcing layer may include a plurality of filaments or yarn strands that extend across the surface of the cushioning structure and are operable to resist fluid-induced elastic strain of the polymer sheet. The outer reinforcement layer enables more direct and directional control of how the cushioning structure expands when inflated with a fluid or when placed under load. Also, the use of external reinforcements may allow the cushioning structure to achieve a greater internal operating pressure at a lower weight than structures without reinforcement. This may then result in greater kinetic energy being returned to the wearer.

In general, the present external reinforcement design may be used with a cushioning structure that includes two or more stacked polymer sheets that are selectively bonded together to define an interior volume that may then be inflated and sealed to form a fluid-filled bladder. The polymer sheets may be bonded together, for example, by increasing the temperature of one or both of the polymer sheets to or above its softening temperature (such as by applying heat, ultrasonic energy, radio frequency energy, infrared energy, or any combination thereof, alone or with pressure, to one or both of the substantially planar sheets). For example, the heat or energy applied to one or both of the substantially planar sheets may be sufficient to soften one or both of the polymeric sheets, once the softened polymeric sheets have been resolidified, heat bonding is produced between the sheets (and between the sheets and any material located therebetween). Similarly, the heat or energy applied to one or both of the substantially planar sheets may be sufficient to melt at least a portion of one or both of the polymeric sheets to melt, thereby producing a particularly strong thermal bond upon resolidification, wherein adjacent polymeric materials at least partially fuse to one another and their polymeric chains become entangled at the fused interface. In some embodiments, the thermal bonding process may be performed via a specially configured mold that contacts the polymer sheet only where thermal bonding is desired. In other embodiments, the heated press may contact the entire sheet or substantially the entire sheet, and the interior bladder volume may be formed by locally inhibiting or blocking thermal bonding of the sheet where the interior volume is desired. In some embodiments, thermal bonding may be prevented or greatly inhibited by printing or otherwise laminating an anti-weld material, such as "barrier ink," between adjacent surfaces of adjacent sheets. In this way, the application of heat, energy, or pressure to the sheet may thermally bond the sheet only in areas where no weld resistant material is present. By including the weld-resistant material only in the interior regions of the sheet (i.e., not extending to the outer periphery of the sheet), the unbonded areas/interstitial spaces may be fully enclosed such that they can be inflated via the introduction of a pressurized fluid. This inflation may cause lateral separation of the sheets by elastic expansion of the polymer sheets. It should be understood that other means of bladder configuration may be similarly used, such as thermoforming/vacuum forming.

In general, the final geometry of the cushioning structure may be a function of the material properties of the polymer sheet, the presence and location of any external reinforcing layers, and the location of the inflatable volume across the sheet (e.g., as may be caused by the placement/location of the anti-weld material between the stacked sheets). More specifically, the final location and shape of the bonding region will define the peripheral contour of the cushioning structure, including the number and presence of any internal chambers, and whether such chambers are in fluid communication with each other.

In embodiments of the present cushioning structure configuration, one or more external reinforcing layers may be added to or otherwise bonded to the outer surface of one or more polymer sheets (or selected portions thereof). In such embodiments, the outer reinforcement layer may generally act as a cage that supports and/or constrains adjacent polymer sheets as the sheets elastically deform as the internal pressure of the volume increases. The external reinforcement may have the effect of changing the final geometry of the cushioning structure and/or the maximum inflation pressure during use, while also reducing the need for the polymer sheet to have the inherent structure required to withstand the pressure. By varying the material, orientation, position and density of the filaments or strands within the reinforcing layer, the expansion/deformation of the sheet during inflation can be controlled and/or varied to distinguish it from a simple unreinforced structure.

In some embodiments, one or more external reinforcing layers may be integrally attached/bonded to the polymer sheet only in the bonding areas where the sheets are thermally bonded together. In more central regions, such as those forming the interior chamber, the outer reinforcing layer may be unattached (e.g., via direct bonding) and may float and/or may be held in place only via the more peripheral bonding regions and the contact pressure between the reinforcing layers.

Referring to the drawings, wherein like reference numbers refer to like components throughout the several views, FIG. 1 shows a fluid-filled bladder 10 included in a sole structure 12 of an article of footwear 14. The article of footwear 14 may include a forefoot region 16, a midfoot region 18, and a heel region 20, with the midfoot region 18 located between the heel region 20 and the forefoot region 16. As will be appreciated by those skilled in the art, the forefoot region 16 is generally located under the toe and metatarsal-phalangeal joints of the covered foot, the midfoot region 18 is generally located under the arch region of the foot, and the heel region 20 is generally located under the calcaneus. The article of footwear 14 has a medial side 22 and a lateral side 24, the medial side 22 being generally shaped to follow the medial side of the wearer's foot, the lateral side 24 being generally shaped to follow the lateral side of the wearer's foot (note that in fig. 1, the medial side 22 is on the opposite side of the article 14 from the visible side-i.e., the lateral side 24).

In one configuration, fluid-filled bladder 10 of the type described herein may be assembled as a midsole or a component of a midsole in sole structure 12. For example, in one configuration, bladder 10 may be a full length bladder that extends through each of forefoot region 16, midfoot region 18, and heel region 20. In some configurations, such full length bladders may be used as an entire midsole. In other embodiments, bladder 10 may be a more discrete cushioning component and/or may include multiple bladders 10 and may be integrated with one or more foam components to form a midsole. In some examples, such discrete bladders may be located within forefoot region 16 and/or heel region 20, but may be omitted from midfoot region 18.

Sole structure 12 is coupled to a footwear upper 26 that defines an interior foot-receiving void 28. In addition, sole structure 12 may include an outsole 30 or an outsole surface that is intended to contact the ground or ground surface 32 when article 14 is worn by an individual during normal stride (i.e., while walking or running).

Fig. 2A and 2B schematically illustrate one embodiment of an external reinforcing fluid-filled bladder 10 that may be used with the present disclosure. As shown, bladder 10 may include or be formed between two or more polymeric sheets (e.g., first polymeric sheet 40 and second polymeric sheet 42) that are fused together at peripheral flange 44 or a bonding region to define an interior volume 46 therebetween (such as shown in cross-section 48 provided in fig. 2B).

For ease of reference, each sheet 40, 42 may have an inner surface 50 that will be referred to as directly defining/abutting the interior volume 46 and an opposite outer surface 52 having a surface normal that extends away from the interior volume 46. The peripheral flange 44 may surround an "inflatable portion 54" that will be referred to as each respective polymer sheet 40, 42. As used herein, the inflatable portion 54 is the portion of the respective polymeric sheet that is surrounded by the peripheral flange 44 and separated from the opposing sheet by a distance to define the interior volume 46. The inflatable portion 54 elastically deforms if/when the interior volume 46 is pressurized via fluid introduced within the interior volume 46. In some embodiments, a plurality of internal volumes 46 may be formed between a single pair of polymer sheets. In such an embodiment, each inflatable portion 54/interior volume 46 would still be surrounded by peripheral flange 44, as the bonding flange would still be peripheral to the volume-even if not peripheral to the polymer sheet.

As further depicted, bladder 10 may include one or more external reinforcing layers 60 in contact with the outer surface 52 of one or both of the first and second polymeric sheets 40, 42. The outer reinforcing layer 60 may include a plurality of constituent reinforcing yarns or yarn strands 62 arranged in a unidirectional, multidirectional, woven, nonwoven, knit, and/or randomized manner and extending through some or all of the respective polymer sheets.

As used herein, the term "filament" is understood to mean a long or substantially continuous strand having a length several orders of magnitude greater than its diameter, and is understood to include fibers. The filaments may be made of naturally occurring materials or of artificial materials, such as synthetic or regenerated materials. The term "yarn" is understood to mean a long or substantially continuous strand of fibers or filaments in a form suitable for knitting, weaving, crocheting, braiding or otherwise interweaving with other yarns or with the same yarn segments, or for sewing including embroidery. Types of yarns include continuous filament yarns, examples of which include monofilament yarns (composed of a single continuous filament) and multifilament yarns (composed of a plurality of flattened or textured filaments that are typically twisted or air-entangled with one another). Spun yarns are another type of yarn consisting of a plurality of staple fibers (such as cotton or wool fibers) or staple fibers or filaments that are entangled with each other during the spinning process. Composite yarns are yet another type of yarn that may be comprised of a string or cable, or it may be comprised of two or more individual strands that are combined into a ply yarn. Natural fibers or threads may be used, including naturally occurring cellulosic fibers such as cotton or flax, naturally occurring protein-based fibers or threads such as wool or silk, and naturally occurring mineral-based materials such as asbestos. Artificial fibers or filaments may be used, including artificial fibers or filaments made of inorganic materials such as glass or metal, as well as fibers or filaments made of regenerated natural polymers including cellulose-based polymers and protein-based polymers, artificial carbon fibers or filaments, and artificial fibers or filaments made of synthetic polymers, i.e. filaments or yarn strands comprising a polymeric material comprising one or more synthetic polymers. in many cases, the synthetic polymer is a thermoplastic (i.e., the filaments or yarn strands are thermoplastic), including thermoplastic elastomers (i.e., the filaments or yarns are thermoplastic and elastomeric), although thermoset materials such as elastic fibers (in which case the filaments or yarns are thermoset) may also be used. A variety of synthetic polymers are commonly used to make fibers or filaments. The polymeric material of the filaments or yarns may include a polymer selected from polyesters such as polyethylene terephthalate (PET), polyamides such as nylon-6, nylon 6, and nylon-11, polyolefins such as propylene homopolymers and copolymers, and ethylene homopolymers and copolymers, and polyacetates such as cellulose acetate fibers, and any combination thereof. Polyurethanes such as thermoplastic polyurethanes and including thermoplastic elastomeric polyurethanes may also be used in the polymeric materials. The filaments or yarn strands may comprise or consist of filaments or yarns comprising natural materials, man-made or regenerated natural materials, or a combination of natural and man-made or regenerated materials, such as spun yarns comprising blends of cotton and polyester fibers, or mixtures of filaments comprising cotton fibers and polyester filaments. The filaments or yarn strands may comprise or consist of multifilament yarns including polyester or polyamide filaments, such as commercially available embroidery threads. The filaments or yarn strands may comprise or consist of bicomponent filaments or yarns, such as a thermoplastic polyurethane sheath covering a polyester or polyamide core.

In many cases, the reinforcing filaments or yarn strands 62 may include one or more polymeric materials having a modulus greater than the corresponding modulus of the polymeric sheet to which they are attached. While in some embodiments, the high modulus wire or yarn strand 62 may be used to effectively lock or prevent any elastic strain in a given direction, in many embodiments the modulus of the wire or yarn strand 62 may be selected to only reduce the amount of elastic strain allowed under typical operating pressures (without completely eliminating it). For example, in some embodiments, the modulus of the filaments or yarn strands 62 may be between 1 and 50 times the modulus of the individual polymer sheets. In other embodiments, the modulus of the filaments or yarn strands 62 may be between 1 and 25x, or between 1 and 20x, or between 1 and 10x, or between 1 and 5x of the modulus of the individual polymer sheets. The wire or yarn strands 62 should also be flexible enough to allow repeated transverse bending without breaking. This flexibility is important to allow for initial inflation of the bladder and to receive repeated compressions during use. In some embodiments, each respective filament or yarn strand 62 may have an aspect ratio of length to diameter of at least 50 or at least 100 or at least 500 or even at least 1000. In other words, the filaments or yarn strands 62 may be continuous strands that may each extend through a portion of the final sheet and not just fibrous fillers that are mixed into the polymer resin prior to forming the layer.

In one configuration, the outer reinforcing layer 60 may comprise a textile. The textile may be a nonwoven textile comprising filaments or yarn strands 62 or consisting of filaments or yarn strands 62. The textile may be a nonwoven textile composed of thermoplastic filaments, such as a hydroentangled nonwoven textile, a spunbond nonwoven textile, a thermally bonded nonwoven textile, a meltblown nonwoven textile, a needle entangled or hydroentangled nonwoven textile, or the like. The textile may be a textile comprising or consisting of interwoven threads or yarn strands, such as knitted, woven, crocheted or braided textile. In one aspect, the textile is a shatter resistant woven fabric. A shatter resistant fabric is typically a woven fabric formed from a plurality of yarn strands that typically include a polymeric material including a polyamide such as polyamide (PA 6). Anti-rupture fabrics generally comprise stronger, and often thicker, reinforcing yarns interwoven at regular intervals throughout the fabric. In some configurations, the outer reinforcement layer 60 may include one or more subsets of unidirectional filaments or yarn strands 62 (i.e., whether woven or not). As used herein, if each constituent yarn or yarn strand 62 has a substantially parallel orientation (i.e., wherein the orientation of the yarn or yarn strand 62 is defined by its longitudinal central axis-typically viewed in plan view and/or prior to inflation of the bladder 10), then a subset of the yarn or yarn strands 62 are unidirectional. As shown in fig. 3, in one configuration, the plurality of filaments or yarn strands 62 can include a first subset 64a of unidirectional filaments or yarn strands extending in a first common direction 66a and a second subset 64b of unidirectional filaments or yarn strands 62 extending in a second common direction 66 b. The first common direction 66a may be oriented at an angle between about 5 degrees and about 90 degrees relative to the second common direction 66 b. In one configuration, these directions 66a, 66b may be approximately orthogonal before the direction in which the cushioning structure expands when inflated.

Although fig. 3 only schematically depicts two sets of unidirectional filaments or yarn strands 62 extending in two directions, it should be understood that the strand arrangement is somewhat design driven and that the buffer structure may have 3 or 4 or 5 or even more sets of unidirectional filaments or yarn strands 62, each set having a unique orientation. Further, in some embodiments, the wire or yarn strand 62 or groups of unidirectional wires or yarn strands 62 may be laid, interwoven, intertwined, woven, intertwined, knitted, crocheted, or braided in a predetermined pattern.

When assembled, the plurality of filaments or yarn strands 62 may extend through and contact the outer surface 52 of the inflatable portion 54 of the polymer sheet 40, 42. In some embodiments, the plurality of filaments or yarn strands 62 in contact with the respective polymer sheets 40, 42 may be secured to the sheets only at the peripheral flange 44/bonding region. In other words, while the filaments or yarn strands 62 may be in direct contact with the outer surface 52 of the inflated portions 54 of the polymeric sheets 40, 42 in this region, they may not be physically attached to the sheets such that relative movement between the yarn strands 62 and the sheets is possible. Conversely, at the peripheral flange 44, the plurality of filaments or yarn strands may be bonded, adhered, welded, and/or physically captured by the polymer sheet, such as by thermal bonding, to inhibit or prevent relative movement. In some embodiments, the bonding may be via the same process used to bond the polymer sheets 40, 42 together, such as by hot pressing or ultrasonic welding.

In one embodiment, the cushioning structure of the present disclosure may be formed by one or more thermoforming and/or vacuum forming processes whereby one or both polymer sheets 40, 42 are drawn into a mold via the application of positive and/or vacuum pressure. After this, the opposing dies can urge the polymer sheets into contact with each other while applying energy to thermally bond the sheets together. The reinforcement layer is introduced into the mold either prior to thermoforming or immediately prior to thermal bonding, such that when the thermal bonding process occurs, the mold also thermally bonds the filaments or yarns of the reinforcement layer to the polymer sheet while creating a bonded peripheral flange.

In another embodiment, such as generally depicted in fig. 4, the cushioning structure 10 may be formed in a substantially planar manner, thereby forming all of the bonds prior to inflating the cushioning structure by filling the cushioning structure with a fluid. For example, in one configuration, the polymer sheets 40, 42 used to form the cushioning structure 10 may be layered into a stacked assembly 202 with the weld resistant material 204 applied to or printed on the interface surface between adjacent sheets 40, 42. In the presence of the weld resistant material (e.g., where the weld resistant material has been printed on adjacent inner sides of one or both of the polymer sheets), the weld resistant material may locally interfere with the ability of the adjacent sheets to thermally bond together, thereby creating an internal groove in which the polymer sheets do not thermally bond to each other, and which may then be filled/pressurized with working fluid. The anti-weld material 204 may include a material (such as a fluid or flowable or printable material, e.g., a barrier ink) that is capable of being selectively deposited on the polymer sheets 40, 42, e.g., via an inkjet printer. Alternatively, the weld resistant material may include a solid that is capable of being selectively deposited on the polymer sheets 40, 42 using a deposition process such as a vapor deposition process or an electrostatic deposition process. In such an example, the computer controlled print head may selectively deposit/print the solder resist material onto the inner surface 50 of the second polymer sheet 42 according to a programmed pattern (e.g., a bitmap or along a vector-based path), wherein bonding between adjacent sheets is not required. The particular printed pattern 206 of anti-weld material 204 may create the geometry of the interior chamber when the bladder 10 is finally inflated.

As further depicted in fig. 4, a reinforcing layer 60 comprising a plurality of filaments or yarn strands 62 may be positioned on one or both sides of the polymer sheets 40, 42 within the stack assembly 202. In some embodiments, the weld resistant material 204 may also be disposed in a pattern 208 on the outer surface 52 of the polymer sheets 40, 42 to prevent bonding of the reinforcing layer 60 to the polymer sheets if a uniform thermal bonding process is utilized. Such a process may be particularly desirable if the filaments or yarn strands 62 comprise a thermoplastic material and a uniform hot pressing process is performed. In this embodiment, the printed outer surface pattern 208 may be consistent with the printed inner surface pattern 206 when assembled. This will prevent the reinforcing layer 60 from bonding to the polymer sheet within the inflatable portion 54 of the bladder 10.

Once the entire stack of alternating sheets and weld-resistant material is prepared and assembled, the stack assembly 202 may then be selectively and/or uniformly hot pressed to thermally bond adjacent surfaces that are free of weld-resistant material together. As described above, the solder resist material 204 interferes with the ability of the sheet to thermally bond anywhere the solder resist material is placed in the process. According to this method, no special thermoforming mold or radio frequency welding is required to form bladder 10. Likewise, if the stack assemblies 202 are uniformly hot pressed together (e.g., such as via a heated iron or a flat press), there may be no need to reconfigure or reconfigure the workstation to create a different cushioning structure configuration. All that needs to happen is the application of a different pattern of solder resist material.

Once bonded, the stack assembly 202 remains flat and the stack assembly 202 assumes the contoured shape of the cushioning structure 10 only when the interior volume 60 formed using the weld-resistant material is inflated by a fluid (e.g., inflation gas) introduced through the optional fill port 220 (i.e., the area shown in fig. 4 as the area to which the weld-resistant material 204 is applied). Once the interior chamber is sufficiently inflated/pressurized, the fill port 220 may then be sealed to entrap fluid within the interior volume, thereby maintaining the inflated bladder shape. If the inflation gas is removed without sealing the fill port 220, and assuming that other components are not disposed in any sealed chamber, and the polymer sheet 200 has not yet been bonded to other components such as the outsole, other midsole layer, or upper, the polymer sheet 200 will likely return to their original flat state (assuming no creep or plastic strain caused by inflation).

In some aspects, the first polymer sheet, the second polymer sheet, or both the first and second polymer sheets comprise a gas barrier material, meaning that the sheet comprises a material having low permeability to gas molecules having low molecular weight, such as nitrogen, oxygen, carbon dioxide gas, and the like. The polymer sheet comprising the gas barrier material may comprise one or more layers of gas barrier material. In such a design, the polymer sheets 40, 42 may be used primarily for the purpose of gas barrier films to contain the internal working gas/fluid, while the reinforcement layer may provide structure for these barrier films. In such a design, the polymer sheet may be composed of barrier material, or may be composed of barrier material layers alternating with thermoplastic elastomer layers, without more resilient material layers that significantly increase the strength, rigidity, and durability of the polymer sheet. This design can be contrasted with existing cushioning structure configurations in which the polymer sheet needs to be formed with sufficient bulk and/or material strength to provide its own structure (e.g., by including forming a thick structural layer from a material that is more resilient than the gas barrier material) while also being resistant to fluid diffusion. In other words, in existing designs, polymeric sheets need to provide a barrier structure and a structure that provides strength, rigidity, and durability to the sheet. In the present design, the strength, rigidity and durability functions are provided and performed primarily by the reinforcement layer and the strands of filaments or yarns 62 extending through the inflatable portion, and thus, in some aspects, the polymer sheet need only act as a gas barrier.

In the present design, the polymeric sheets 40, 42 may include or consist of polymeric materials of various polymers. The polymeric material of the polymeric sheets 40, 42 may be a thermoplastic material, such as a thermoplastic elastomer material. The polymer sheets 40, 42 may include a gas barrier material. The polymer sheets 40, 42 may include a thermoplastic elastomer material and a gas barrier material, and the two materials may be structured in the polymer sheets, for example in alternating layers, to form a barrier film so that the polymer sheets may resiliently hold a fluid, such as air or another gas. In one aspect, the polymeric sheets 40, 42 used to form the balloons or bladders disclosed herein include or consist of a barrier film 240, such as shown in the schematic cross-sectional view in fig. 2B. As used herein, a barrier film is understood to be a film having relatively low fluid transmittance. The barrier film resiliently retains fluid when used alone or in combination with other materials in the balloon or balloons. Depending on the structure and use of the buffer structure, the barrier film may maintain the fluid at a pressure above, at, or below atmospheric pressure. In some aspects, the fluid is a liquid or a gas. Examples of the gas include air, oxygen (O ₂) and nitrogen (N ₂) and inert gases. In one aspect, the barrier material of the barrier film is a nitrogen barrier material.

The barrier film may have a gas transmission rate of less than 4 or less than 3 or less than 2 cubic centimeters per square meter per atmosphere per day for films having a thickness of about 72 micrometers to about 320 micrometers when measured at 23 degrees celsius and a relative humidity of 0 percent. In another example, the barrier film has a gas transmission rate of from about 0.1 to about 3, or from about 0.5 to about 3 cubic centimeters per square meter per atmosphere per day for a film having a thickness of about 72 micrometers to about 320 micrometers, as measured at 23 degrees celsius and a relative humidity of 0 percent. Gas permeability, such as oxygen or nitrogen permeability, may be measured using ASTM D1434.

In one aspect, the barrier film may comprise a multilayer film comprising a plurality of layers, the plurality of layers comprising one or more barrier layers, the one or more barrier layers comprise a barrier material comprising or consisting essentially of one or more gas barrier compounds. The multilayer film comprises at least 5 layers or at least 10 layers. Optionally, the multilayer film comprises from about 5 to about 200 layers, from about 10 to about 100 layers, from about 20 to about 80 layers, from about 20 to about 50 layers, or from about 40 to about 90 layers.

In one aspect, the barrier material comprises or consists essentially of one or more inorganic gas barrier compounds. The one or more inorganic gas barrier compounds may take the form of fibers, particles, platelets, or a combination thereof. The fibers, particles, platelets may comprise or consist essentially of nanoscale fibers, particles, platelets, or a combination thereof. Examples of inorganic barrier compounds include, for example, carbon fibers, glass flakes, silica, silicates, calcium carbonate, clays, mica, talc, carbon black, particulate graphite, metal flakes, and combinations thereof. The inorganic gas barrier component may comprise or consist essentially of one or more clays. Examples of suitable clays include bentonite, montmorillonite, kaolinite, and mixtures thereof. In one example, the inorganic gas barrier component consists of clay. Optionally, the barrier material may also include one or more additional ingredients, such as polymers, processing aids, colorants, or any combination thereof. In aspects where the barrier material comprises or consists essentially of one or more inorganic barrier compounds, the barrier material may be described as comprising an inorganic gas barrier component consisting of all inorganic barrier compounds present in the barrier material. When one or more inorganic gas barrier compounds are included in the barrier material, the total concentration of inorganic gas barrier components present in the barrier material may be less than 60 wt%, or less than 40 wt%, or less than 20 wt% of the total composition. Alternatively, in other examples, the barrier material consists essentially of one or more inorganic gas barrier materials.

In one aspect, the gas barrier compound comprises or consists essentially of one or more gas barrier polymers. The one or more gas barrier polymers may include thermoplastic polymers. In one example, the barrier material may comprise or consist essentially of one or more thermoplastic polymers, which means that the barrier material comprises or consists essentially of a plurality of thermoplastic polymers, including thermoplastic polymers that are not gas barrier polymers. In another example, the barrier material comprises or consists essentially of one or more thermoplastic gas barrier polymers, meaning that all polymers present in the barrier material are thermoplastic gas barrier polymers. The barrier material may be described as including a polymer component consisting of all of the polymers present in the barrier material. For example, the polymer component of the barrier material may be composed of a single class of gas barrier polymers, such as, for example, one or more polyolefins, or may be composed of a single type of gas barrier polymer, such as, for example, one or more ethylene vinyl alcohol copolymers. Optionally, the barrier material may also include one or more non-polymeric additives, such as one or more fillers, processing aids, colorants, or combinations thereof.

Many gas barrier polymers are known in the art. Examples of the gas barrier polymer include vinyl polymers such as vinylidene chloride polymers, acrylic polymers such as acrylonitrile polymers, polyamides, epoxy polymers, amine polymers, polyolefins such as polyethylene and polypropylene, copolymers thereof such as ethylene-vinyl alcohol copolymers, and mixtures thereof. Examples of thermoplastic gas barrier polymers include thermoplastic vinyl homopolymers and copolymers, thermoplastic acrylic homopolymers and copolymers, thermoplastic amine homopolymers and copolymers, thermoplastic polyolefin homopolymers and copolymers, and mixtures thereof. In one example, the one or more gas barrier polymers comprise or consist essentially of one or more thermoplastic polyethylene copolymers, such as, for example, one or more thermoplastic ethylene-vinyl alcohol copolymers. The one or more ethylene vinyl alcohol copolymers may include an ethylene content of from about 28 mole% to about 44 mole%, or an ethylene content of from about 32 mole% to about 44 mole%. In yet another example, the one or more gas barrier polymers may include or consist essentially of one or more polyethylenimine, polyacrylic acid, polyethylene oxide, polyacrylamide, polyamidoamine, or any combination thereof.

The polymer sheets of the present disclosure are elastomeric. In some aspects, the polymeric sheet is comprised of one or more elastomeric materials, wherein the elastomeric materials individually comprise a polymeric component that comprises or consists of one or more elastomeric polymers, such as one or more thermoplastic elastomers. In other words, in some aspects, the polymeric sheet comprises one or more layers of elastomeric material and is free of the gas barrier materials described herein. In other aspects, the polymeric sheet is a multilayer film comprising layers of gas barrier material alternating with layers of elastomeric material, wherein the elastomeric material comprises a polymeric component comprising or consisting essentially of at least one elastomer. Many gas barrier compounds are brittle and/or relatively hard and, thus, one or more barrier layers may be prone to cracking when subjected to repeated, excessive stress loads, such as may be generated during flexing and release of the multilayer film. A multilayer film comprising one or more barrier layers alternating with a second layer of elastomeric material produces a multilayer film that is better able to withstand repeated flexing and release while maintaining its gas barrier properties than a film without an elastomeric second layer.

The elastomeric material comprises or consists of a polymer component, wherein the polymer component comprises or consists essentially of one or more elastomers. In one aspect, the polymer component of the elastomeric material comprises or consists essentially of one or more thermoplastic elastomers. The elastomeric material may be described as including a polymer component that is composed of all of the polymers present in the elastomeric material. In one example, the polymer component of the elastomeric material is composed of one or more elastomers. Optionally, the elastomeric material may also include one or more non-polymeric additives, such as fillers, processing aids, and/or colorants.

Many polymers suitable for use in elastomeric materials are known in the art. Exemplary polymers that can be included in the elastomeric material include polyolefins, polyamides, polycarbonates, polyimides, polyesters, polyacrylates, polyesters, polyethers, polystyrene, polyureas, and polyurethanes, including homopolymers and copolymers thereof (e.g., polyolefin homopolymers, polyolefin copolymers, and the like), and combinations thereof. In one example, the elastomeric material comprises or consists essentially of one or more polymers selected from the group consisting of polyolefins, polyamides, polyesters, polystyrene, and polyurethanes, including homopolymers and copolymers thereof, and combinations thereof. In another example, the polymeric component of the elastomeric material is comprised of one or more thermoplastic polymers or one or more elastomers or one or more thermoplastic elastomers, including thermoplastic vulcanizates. Alternatively, the one or more polymers of the elastomeric material may include one or more thermoset or thermosettable elastomers such as, for example, natural rubber and synthetic rubber, including butadiene rubber, isoprene rubber, silicone rubber, and the like.

Polyolefins are a class of polymers comprising monomer units derived from simple olefins such as ethylene, propylene and butene. The polymer component of the elastomeric material may include or consist of one or more polyolefin elastomers, including one or more thermoplastic polyolefin elastomers. Examples of thermoplastic polyolefins include polyethylene homopolymers, polypropylene copolymers (including polyethylene-polypropylene copolymers), polybutenes, ethylene-octene copolymers, olefin block copolymers, propylene-butane copolymers, and combinations thereof, including blends of polyethylene homopolymers and polypropylene homopolymers. Examples of polyolefin elastomers include polyisobutylene elastomers, poly (alpha-olefin) elastomers, ethylene propylene diene monomer elastomers, and combinations thereof.

Polyamides are a class of polymers comprising monomer units linked by amide linkages. Naturally occurring polyamides include proteins such as wool and silk and synthetic amides such as nylon and aromatic polyamides. The one or more polymer components of the elastomeric material may include thermoplastic polyamides, such as nylon 6, nylon 6-6, nylon-11, and thermoplastic polyamide copolymers. The polyamide may be a polyamide elastomer, such as a thermoplastic polyamide elastomer.

Polyesters are a class of polymers comprising monomer units derived from ester functionality and are typically prepared by condensing a dibasic acid such as, for example, terephthalic acid with one or more polyols. In one example, the second material may comprise or consist essentially of one or more thermoplastic polyester elastomers. Examples of polyester polymers include homopolymers such as polyethylene terephthalate, polybutylene terephthalate, poly-1, 4-cyclohexylene-dimethylene terephthalate, and copolymers such as polyester polyurethane. The polymer component of the elastomeric material may include or consist of a polyester elastomer, such as a thermoplastic polyester elastomer.

Styrenic polymers are a class of polymers that include monomer units derived from styrene. The one or more second polymers may comprise, consist essentially of, or consist of a styrenic homopolymer, a styrenic random copolymer, a styrenic block copolymer, or a combination thereof. Examples of styrenic polymers include styrenic block copolymers such as acrylonitrile butadiene styrene block copolymers, styrene acrylonitrile block copolymers, styrene ethylene butylene styrene block copolymers, styrene ethylene butadiene styrene block copolymers, styrene ethylene propylene styrene block copolymers, styrene butadiene styrene block copolymers, and combinations thereof. The polymer component of the elastomeric material may include or consist of a styrenic elastomer, such as a thermoplastic styrenic elastomer.

Polyurethanes are a class of polymers comprising monomer units linked by urethane linkages. Polyurethanes are most often formed by reacting a polyisocyanate (e.g., a diisocyanate or triisocyanate) with a polyol (e.g., a diol or triol), optionally in the presence of a chain extender. Monomeric units derived from polyisocyanates are often referred to as hard segments of polyurethanes, while monomeric units derived from polyols are often referred to as soft segments of polyurethanes. The hard segments may be derived from aliphatic polyisocyanates, or organic isocyanates, or mixtures of both. The soft segment may be derived from a saturated polyol, or an unsaturated polyol such as a polydiene polyol, or a mixture of both. When the multilayer film is bonded to a natural or synthetic rubber, including soft segments derived from one or more polydiene polyols, the bonding between the rubber and the film may be promoted when the rubber and the film are crosslinked in contact with each other, such as in a vulcanization process. The polymer component of the elastomeric material may include or consist of a polyurethane elastomer, such as a thermoplastic polyurethane elastomer.

Barrier films, including multilayer films, have a total thickness of from about 40 microns to about 500 microns, or from about 50 microns to about 400 microns, or from about 60 microns to about 350 microns. In one aspect, each individual layer of the plurality of layers of the multilayer film has a thickness from about 0.001 microns to about 10 microns. For example, the thickness of the individual barrier layers may range from about 0.001 microns to about 3 microns thick, or from about 0.5 microns to about 2 microns thick, or from about 0.5 microns to about 1 micron thick. The thickness of the individual second layers may range from about 2 microns to about 8 microns thick, or from about 2 microns to about 4 microns thick. The thickness of the films and/or their individual layers may be measured by any method known in the art, such as, for example, ASTM E252, ASTM D6988, ASTM D8136, or using an optical or electron microscope.

The polymeric sheet comprising the multilayer film has a shore hardness of from about 35A to about 95A, alternatively from about 55A to about 90A. Hardness can be measured using the shore a scale using ASTM D2240.

When a polymer sheet is formed using a coextrusion process, such as when the barrier film is formed from a plurality of alternating barrier layers and second layers, the barrier material may have a melt flow index of from about 5 to about 7 grams/10 minutes at 190 degrees celsius when a weight of 2.16 kilograms is used. When used alone or in combination with a barrier material, the elastomeric material may have a melt flow index of from about 20 to about 30 grams/10 minutes at 190 degrees celsius when a weight of 2.16 kilograms is used. In a further aspect, when a layered film comprising a barrier material is used, the melt flow index of the barrier material may be from about 80% to about 120% of the melt flow index of the elastomeric material per 10 minutes when measured at 190 degrees celsius when a weight of 2.16 kilograms is used. In these aspects, the melt flow index may be measured using ASTM D1238. Alternatively or additionally, the barrier material or the elastomeric material, or both, have a melting temperature from about 165 degrees celsius to about 183 degrees celsius, or from about 155 degrees celsius to about 165 degrees celsius. The barrier material may have a melting temperature of from about 165 degrees celsius to about 183 degrees celsius. The elastomeric material may have a melting temperature of about 155 degrees celsius to about 165 degrees celsius. The melting temperature may be measured using ASTM D3418.

In some embodiments, the reinforcing filaments or yarn strands 62 may be formed from a polymeric material comprising a polymer selected from the group consisting of polyamides, polyesters, polyurethanes, polyolefins, and combinations thereof. In other embodiments, the filaments or yarn strands 62 may include carbon fibers, glass spun fibers, and the like. The filaments or yarn strands 62 may be selected to meet certain minimum durability requirements for a given intended use.

Although each constituent yarn or yarn strand 62 may be laid down individually, if the yarn or yarn strands 62 are co-located across the polymer sheet, manufacturing efficiency and production cycle time may be improved. Co-location may be achieved by using unidirectional plies, a stack of multiple unidirectional plies (i.e., each having a different co-orientation), a textile including a nonwoven textile, a woven fabric, a knitted fabric, a crochet fabric, and the like. In some embodiments, to facilitate bonding with the polymer sheets 40, 42, the strands or filaments 62 of the reinforcing layer may be coated or impregnated with a thermoplastic material prior to thermal bonding to the polymer sheets.

In some embodiments, the wire or yarn strand 62 may exhibit a non-linear stretch profile such that the effective modulus of the wire or yarn strand 62 increases significantly after a certain amount of strain. These strands 62 may include strands 62 of wire or yarn, or a configuration of strands 62 of wire or yarn having non-linear elasticity, wire or yarn having very low or no elongation, coiled wire or yarn, loosely woven or knitted yarn, or the like. For a non-linear stretch profile, the cushioning structure 10 may more readily inflate during initial introduction of the pressurized fluid, but once a threshold inflation is reached, the characteristics of the filaments or yarn strands 62 or the characteristics of the configuration of the filaments or yarn strands 62 may engage or stiffen and help the cushioning structure resist further inflation.

In some embodiments, in addition to structurally reinforcing the cushioning structure, the reinforcing layer may be used to help secure the cushioning structure to an adjacent component. For example, in one configuration, a wire or yarn strand 62, or a textile including a wire or yarn strand 62, may be used to secure the cushioning structure to an adjacent component. For example, the filaments or yarn strands 62 or a textile comprising the filaments or yarn strands 62 may be used to thermally bond or knit, weave, or stitch the cushioning structure to another component, such as an adjacent textile.

The cushioning structure may expand when inflated, at least in part, based on the elasticity of the material of the polymer sheet. If the outer reinforcing layer 60 is oriented to provide a sheet having a substantially isotropic in-plane elastic modulus, the dimensional expansion of the cushioning structure should be approximately uniform and symmetrical, such as shown in fig. 2A and 2B. In such embodiments, the final geometry of bladder 10 may be similar to a bladder omitting wire or yarn strands 62, however, the internal fluid pressure required to achieve equal or similar lateral deformation will also increase as the modulus of the polymeric material increases. For example, in a non-reinforced design, the maximum operating pressure of the cushioning structure may be about 15 to 20psi, while in a reinforced configuration, the operating pressure to achieve a similar shape may be about 40 to 50psi. At higher operating pressures, the cushioning structure may more effectively return energy to the wearer of the article of footwear including the cushioning structure during an action such as running, jumping, or cutting, wherein dynamic impact loads are applied to bladder 10.

While the ability to achieve increased working pressure is one benefit of the external reinforcement, in other embodiments, the spacing, arrangement, and/or elasticity of the constituent yarn strands 62 may be used to alter the inflation dynamics and/or final geometry of the bladder. More specifically, by applying the reinforcing layer only to selected regions of the polymer sheet, the modulus of elasticity in these regions may be increased, which may result in greater localized working pressures or relatively smaller inflation displacements than in regions lacking the reinforcing layer. In addition, by controlling the direction of the filaments or strands 62, an anisotropic inflation/stretching dynamics may be introduced.

Fig. 5A and 5B schematically illustrate an article of footwear 300 having a sole structure 12, wherein sole structure 12 has a plurality of discrete reinforcing bladders 302. In the illustrated embodiment, three pods fluidly connected to the chamber are provided. A first pod 304 having six discrete chambers 306 is provided in heel region 20 of sole structure 12, a second pod 308 having three chambers 306 is provided in forefoot region 16 on medial side 22 of sole structure 12, and a third pod 310 having three chambers 306 is provided in forefoot region 16 on lateral side 24 of sole structure 12. In this design, each chamber 306 may be externally reinforced on the outside of the upper/uppermost polymer sheet 312 and the lower/lowermost polymer sheet 314.

As best shown in the schematic exploded view 320 provided in fig. 16B, each of the three pod pods 304, 308, 310 may be disposed between an upper plate 322 and a lower plate 324. These plates 322, 324 are sufficiently rigid to cause compression of the respective bladder chambers when dynamic compression/impact loads are applied via the wearer's foot. In this embodiment, each pod may be maintained at a static pressure of between about 30psi and about 60 psi. In some embodiments, to concentrate the compressive load more on each chamber 306, each chamber 306 may be mounted between opposing posts 326. Each post 326 may have a diameter (or more generally, perimeter) that is less than a corresponding diameter (or perimeter) of the chamber 306. In some embodiments, the diameter or circumference of the post 326 may be less than about 70% of the diameter or circumference of the chamber 306. In other embodiments, the diameter or circumference of the post 326 may be less than about 50% of the diameter or circumference of the chamber 306. While columns are not strictly required to take advantage of these designs, as the internal pressure of the bladder increases, load concentrating/pressure increasing features may be required to increase the amount of compression deformation during an impact.

In the designs provided in fig. 5A and 5B, sole structure 12 may also include one or both of an upper midsole cushioning member 330 between upper plate 322 and upper 26 and a lower midsole cushioning member 332 between lower plate 324 and outsole 30. These midsole cushioning members 330, 332 may be formed from a foamed polymeric material that is selected to dampen the impact forces while desirably returning energy to the wearer's foot upon rebound from the impact. Referring again to fig. 5A, in some embodiments, the lower and/or upper posts 326 may be at least partially hidden from view by recessing the respective plates 322, 324 into the upper/lower midsole cushioning members 330, 332. In the illustrated embodiment, lower plate 324 is recessed into lower midsole cushioning member 332 to a point where the coupling flange 44 of the bladder is approximately flush with the top of lower midsole cushioning member 332.

While the present disclosure generally focuses on integrating multiple reinforcing fibers into a polymeric sheet forming a bladder, in some embodiments additional films or sheets having linear or non-linear stiffness may be provided locally or regionally in a similar manner to alter the dimensional stiffness in the polymeric sheet.

To assist and clarify the description of various embodiments, various terms are defined herein. The following definitions apply throughout the specification (including the claims) unless otherwise specified. In addition, all references cited herein are incorporated by reference in their entirety.

"Article of footwear," "article of footwear," and "footwear" may be considered machines and manufacture. The assembled articles of footwear (e.g., shoes, sandals, boots, etc.) ready to wear, as well as discrete components of the articles of footwear (e.g., midsole, outsole, upper components, etc.), are considered herein and are alternatively referred to as "articles of footwear" in the singular or plural.

"A," "an," "the," "at least one," and "one or more" are used interchangeably to indicate that at least one item is present. There may be a plurality of such items unless the context clearly indicates otherwise. Unless the context, including the claims, clearly or explicitly stated otherwise in the claims, all numbers in this description (e.g., amounts or conditions) are to be understood as modified in all instances by the term "about" whether or not "about" actually appears before the number. "about" indicates that the stated value allows some slight imprecision (with values close to being accurate; close or reasonably close to the value; almost). If the imprecision provided by "about" is not otherwise understood in the art with this ordinary meaning, then "about" as used herein at least indicates a change that may be caused by ordinary methods of measuring and using such parameters. Moreover, the disclosure of a range is to be understood as specifically disclosing all values and further divided ranges within the range.

The terms "comprises," "comprising," "including," and "having" are inclusive and thus specify the presence of stated features, steps, operations, elements, or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, or components. The order of steps, processes, and operations may be changed when possible, and additional or alternative steps may be employed. As used in this specification, the term "or" includes any and all combinations of the associated listed items. The term "any of the terms" is to be understood to include any possible combination of the referenced items, including "any of the referenced items". The term "any of the claims" is to be understood as including any possible combination of the referenced claims of the appended claims, including any one of the referenced claims ".

For consistency and convenience, directional adjectives may be employed throughout the detailed description corresponding to the depicted embodiments. Those of ordinary skill in the art will recognize that terms such as "above," "below," "upward," "downward," "top," "bottom," etc., are used descriptively with respect to the figures, and do not represent limitations on the scope of the invention, as defined by the claims.

The term "longitudinal" refers to a direction extending along the length of a component. For example, the longitudinal direction of the shoe extends between the forefoot region and the heel region of the shoe. The term "forward" or "anterior" is used to refer to the general direction from the heel region toward the forefoot region, while the term "posterior" or "posterior" is used to refer to the opposite direction, i.e., the direction from the forefoot region toward the heel region. In some cases, a component may be identified as having a longitudinal axis and a front-to-back longitudinal direction along the axis. The longitudinal direction or axis may also be referred to as a front-to-back direction or axis.

The term "transverse" refers to a direction extending along the width of a component. For example, the lateral direction of the shoe extends between the lateral side and the medial side of the shoe. The lateral direction or axis may also be referred to as a lateral direction or axis or a medial-lateral direction or axis.

The term "vertical" refers to a direction that is substantially perpendicular to the lateral and longitudinal directions. For example, in the case of a sole lying on a ground surface, the vertical direction may extend upwardly from the ground surface. It should be understood that each of these directional adjectives may be applied to individual components of the sole. The term "upward" or "upwardly" refers to a vertical direction that points toward the top of the component, which may include the instep, the fastening area, and/or the throat of the upper. The term "downward" or "downwardly" refers to a vertical direction that points toward the bottom of the component opposite the upward direction, and may generally point toward the bottom of the sole structure of the article of footwear.

An "interior" of an article of footwear, such as a shoe, refers to the portion of the space occupied by the wearer's foot when the shoe is worn. "medial" side of a component refers to the side or surface of the component that is (or will be) oriented toward the component or the interior of the article of footwear in the assembled article of footwear. "lateral" or "exterior" of a component refers to the side or surface of the component that is oriented away (or will be away) from the interior of the shoe in the assembled shoe. In some cases, other components may be between the medial side of the component and the interior of the assembled article of footwear. Similarly, other components may be between the lateral side of the component and the space outside of the assembled article of footwear. Furthermore, the terms "inwardly" and "inwardly" refer to directions toward the interior of a component or article of footwear, such as a shoe, and the terms "outwardly" and "outwardly" refer to directions toward the exterior of a component or article of footwear, such as a shoe. Further, the term "proximal" refers to a direction closer to the center of the footwear component, or to the foot when the foot is inserted into the footwear article when the footwear article is worn by a user. Likewise, the term "distal" refers to a relative position that is further away from the center of the footwear component, or further away from the foot when the foot is inserted into the article of footwear when the article of footwear is worn by a user. Thus, the terms proximal and distal are to be understood as providing generally opposite terms to describe relative spatial positions.

While various embodiments have been described, the description is intended to be exemplary, rather than limiting, and it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible that are within the scope of the embodiments. Any feature of any embodiment may be used in combination with or in place of any other feature or element in any other embodiment unless explicitly limited. Accordingly, these embodiments are not limited except as by the appended claims and their equivalents. Further, various modifications and changes may be made within the scope of the appended claims.

While several modes for carrying out the various aspects of the present teachings have been described in detail, those familiar with the art to which these teachings relate will recognize various alternative aspects for practicing the present teachings within the scope of the appended claims. It is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and exemplary of the full scope of alternative embodiments that will be recognized by those skilled in the art as being implied, structural and/or functional equivalents to or otherwise apparent from the inclusion and not limited to only those explicitly depicted and/or described embodiments.

The following clauses present various embodiments of the present technology and are intended to be read in light of the foregoing disclosure and accompanying drawings.

Clause 1. A cushioning structure comprising an outer reinforcing bladder comprising a first polymer sheet and a second polymer sheet, each polymer sheet comprising an inner surface and an opposing outer surface, a first reinforcing layer in contact with the outer surface of the first polymer sheet, the first reinforcing layer having a greater modulus than the first polymer sheet, and a second reinforcing layer in contact with the outer surface of the second polymer sheet, the second reinforcing layer having a greater modulus than the second polymer sheet, and wherein the bladder comprises one or more chambers where the inner surface of the first polymer sheet is spaced apart from the inner surface of the second polymer sheet to define an interior volume between the first polymer sheet and the second polymer sheet, one or more bonding regions where the inner surface of the first polymer sheet is in contact with the second polymer sheet, and a second reinforcing layer in contact with the outer surface of the second polymer sheet, where the inner surface of the first polymer sheet is in contact with the second polymer sheet, and wherein the second polymer sheet is bonded to only the outer peripheral flange where the first polymer sheet is bonded to the outer peripheral flange.

Clause 2 the cushioning structure of clause 1, further comprising a weld resistant material disposed between the first and second polymeric sheets within a central region of the first and second polymeric sheets, the weld resistant material operable to inhibit thermal fusion of the first polymeric sheet with the second polymeric sheet wherever the weld resistant material is present;

clause 3 the cushioning structure of clause 1, further comprising a fluid provided within the interior volume, and wherein the fluid is pressurized to a relative pressure of from about 20psi to about 60 psi.

Clause 4 the cushioning structure of clause 1, wherein the first polymer sheet comprises a first inflatable portion and the second polymer sheet comprises a second inflatable portion, wherein the interior volume is formed between the first inflatable portion and the second inflatable portion, and wherein the peripheral flange surrounds both the first inflatable portion and the second inflatable portion, wherein the first reinforcement layer contacts the first inflatable portion but is not directly bonded to the first inflatable portion, and wherein the second reinforcement layer contacts the second inflatable portion but is not directly bonded to the second inflatable portion.

Clause 5 the cushioning structure of clause 1, wherein the first and second reinforcing layers each comprise a plurality of filaments or yarn strands, and wherein each filament or yarn strand is bonded to the peripheral flange.

Clause 6. The buffer structure of clause 5, wherein the plurality of filaments or yarn strands comprises a first set of unidirectional filaments or yarn strands each extending in a first direction and a second set of unidirectional filaments or yarn strands each extending in a second direction different from the first direction.

Clause 7. The cushioning structure of clause 6, wherein the first reinforcing layer comprises a woven textile comprising a first set of unidirectional yarn strands woven with a second set of unidirectional yarn strands.

Clause 8 the cushioning structure of clause 1, wherein each of the first and second polymeric sheets comprises a thermoplastic material comprising one or more thermoplastic polymers.

Clause 9 the cushioning structure of clause 8, wherein the first reinforcing layer and the second reinforcing layer each comprise a plurality of filaments or yarn strands, wherein each individual filament or yarn strand of the plurality of filaments or yarn strands is bonded to the peripheral flange, and wherein each individual filament or yarn strand of the plurality of yarn strands comprises a thermoplastic material.

Clause 10. The cushioning structure of clause 9, wherein the each individual filament or yarn strand of the plurality of yarn strands is thermoplastic, or thermoplastic and elastomeric.

Clause 11 the cushioning structure of clause 1, further comprising a non-foamed polymer upper plate disposed on a first side of the bladder and a non-foamed polymer lower plate disposed on an opposite second side of the bladder, wherein each of the upper plate and the lower plate is in contact with the bladder and is operable to apply a compressive load to the bladder.

Clause 12 the cushioning structure of clause 11, wherein the upper plate comprises an upper plate portion and a first plenum projection, wherein the first plenum projection extends from the upper plate portion toward the lower plate and is in contact with a central region of the first polymer sheet, and wherein the lower plate comprises a lower plate portion and a second plenum projection, wherein the second plenum projection extends from the lower plate portion toward the upper plate and is in contact with a central region of the second polymer sheet, and wherein the first plenum projection and the second plenum projection are operable to strike the bladder when a compressive load is applied between the upper plate and the lower plate.

Clause 13 the cushioning structure of clause 12, further comprising a polymeric foam cushioning element in contact with the upper plate on a side of the plate opposite the bladder.

Clause 14 the cushioning structure of clause 1, further comprising a weld resistant material between the outer surface of the first polymeric sheet and the first reinforcing layer and between the outer surface of the second polymeric sheet and the second reinforcing layer.

Clause 15. The cushioning structure of clause 1, wherein the cushioning structure is a cushioning structure for an article of apparel or athletic equipment.

Clause 16 the cushioning structure of clause 1, wherein the cushioning structure is a sole structure for an article of footwear or is a component of a sole structure of an article of footwear.

Clause 17 an article of footwear, apparel, or athletic equipment comprising a cushioning structure according to any of clauses 1-17.

Clause 18. A method of making a cushioning structure, the method comprising forming an outer reinforcing bladder by assembling a stack comprising first polymer sheets, second polymer sheets, a first reinforcing layer and a second reinforcing layer, wherein in the assembled stack, each polymer sheet comprises an inner surface and an opposing outer surface, the first reinforcing layer is in contact with the outer surface of the first polymer sheet, the first reinforcing layer has a greater modulus than the first polymer sheet, the second reinforcing layer is in contact with the outer surface of the second polymer sheet, the second reinforcing layer has a greater modulus than the second polymer sheet, and bonding together the layers of the assembled stack into the outer reinforcing bladder, wherein the inner surface of the first polymer sheet is spaced apart from the inner surface of the second polymer sheet at the one or more chambers to define an inner volume between the first polymer sheet and the second polymer sheet, the second reinforcing layer is in contact with the outer surface of the second polymer sheet only, the first reinforcing layer is bonded to the outer surface of the outer polymer sheet only in the inner peripheral flange, the first reinforcing layer is bonded to the outer peripheral flange in the peripheral flange, and the second reinforcing layer is bonded to the outer peripheral flange in the peripheral flange only at the peripheral flange.

Clause 19 the method of clause 18, wherein the bonding step comprises thermally bonding by softening or melting the first polymer sheet, the second polymer sheet, or both the first polymer sheet and the second polymer sheet.

Clause 20 the method of clause 18, wherein the cushioning structure is a cushioning structure for an article of footwear, apparel, or athletic equipment.

Claims

1. A buffer structure, comprising:

An externally reinforced bladder, the bladder comprising:

a first polymer sheet and a second polymer sheet, each polymer sheet comprising an inner surface and an opposing outer surface;

a first reinforcement layer in contact with an outer surface of the first polymer sheet, the first reinforcement layer having a greater modulus than the first polymer sheet; and

a second reinforcement layer in contact with an outer surface of the second polymer sheet, the second reinforcement layer having a greater modulus than the second polymer sheet; and

wherein the capsule comprises:

one or more interior volumes at which an interior surface of the first polymer sheet is spaced apart from an interior surface of the second polymer sheet to define the interior volume between the first polymer sheet and the second polymer sheet;

one or more peripheral flanges where the inner surface of the first polymer sheet contacts and is bonded to the inner surface of the second polymer sheet, and wherein each of the one or more peripheral flanges surrounds a respective one of the one or more interior volumes;

wherein in said bladder, said first reinforcement layer is bonded to said first polymer sheet only at said peripheral flange;

The second reinforcement layer is bonded to the second polymer sheet only at the peripheral flange.

2. The buffer structure according to claim 1, further comprising:

an anti-welding material disposed between the first polymer sheet and the second polymer sheet within a central region of the first polymer sheet and the second polymer sheet, wherein the central region of the first polymer sheet is aligned with the central region of the second polymer sheet to define the interior volume therebetween, and wherein the anti-welding material is operable to inhibit thermal fusing of the first polymer sheet to the second polymer sheet wherever the anti-welding material is present.

3. The cushioning structure of claim 1, further comprising a fluid disposed within the interior volume, and wherein the fluid is pressurized to a relative pressure of from about 20 psi to about 60 psi.

4. The cushioning structure of claim 1 , wherein each of the first polymer sheet and the second polymer sheet includes a respective central region, wherein the interior volume is formed between the central region of the first polymer sheet and the central region of the second polymer sheet, and wherein the peripheral flange surrounds both the central region of the first polymer sheet and the central region of the second polymer sheet;

wherein the first reinforcement layer contacts the central region of the first polymer sheet but is not directly bonded to the central region of the first polymer sheet;

Wherein the second reinforcement layer contacts the central region of the second polymer sheet but is not directly bonded to the central region of the second polymer sheet.

5. The cushioning structure of claim 1, wherein the first reinforcement layer and the second reinforcement layer each comprise a plurality of filaments or yarn strands, and wherein each filament or yarn strand is bonded to the peripheral flange.

6. A buffering structure according to claim 5, wherein the plurality of threads or yarn strands include a first group of unidirectional threads or yarn strands and a second group of unidirectional threads or yarn strands, each of the first group of unidirectional threads or yarn strands extending along a first direction, and each of the second group of unidirectional threads or yarn strands extending along a second direction different from the first direction.

7. The cushioning structure of claim 6, wherein the first reinforcement layer comprises a woven textile comprising a first set of unidirectional yarn strands woven with a second set of unidirectional yarn strands.

8. The cushioning structure of claim 1 , wherein the first polymer sheet comprises a first thermoplastic material and the second polymer sheet comprises a second polymer material;

Wherein the first thermoplastic material is the same as the second thermoplastic material, or wherein the first thermoplastic material is different from the second thermoplastic material.

9. The cushioning structure of claim 8, wherein the first reinforcement layer and the second reinforcement layer each comprise a plurality of filaments or yarn strands;

wherein each individual thread or yarn strand of said plurality of threads or yarn strands is bonded to said peripheral flange; and

Wherein each individual filament or yarn strand of the plurality of yarn strands comprises a thermoplastic material.

10. The cushioning structure of claim 9, wherein each individual filament or yarn strand of the plurality of yarn strands is thermoplastic, or thermoplastic and elastomeric.

11. The cushioning structure of claim 1 , further comprising an upper polymer plate disposed on a first side of the bladder and a lower non-foamed polymer plate disposed on an opposing second side of the bladder;

Each of the upper plate and the lower plate is in contact with the bladder and is operable to apply a compressive load to the bladder.

12. The cushioning structure according to claim 11, wherein the upper plate comprises an upper plate portion and a first pressurizing protrusion, wherein the first pressurizing protrusion extends from the upper plate portion toward the lower plate and contacts the central area of the first polymer sheet;

wherein the lower plate comprises a lower plate portion and a second pressurizing protrusion, wherein the second pressurizing protrusion extends from the lower plate portion toward the upper plate and contacts a central area of the second polymer sheet;

Wherein the first and second pressurizing projections are operable to impact the bladder when a compressive load is applied between the upper plate and the lower plate.

13. The cushioning structure of claim 12 further comprising a polymer foam cushioning element in contact with the upper plate on a side of the upper plate opposite the bladder.

14. The cushioning structure of claim 1, further comprising a weld-resistant material between an outer surface of the first polymer sheet and the first reinforcement layer and between an outer surface of the second polymer sheet and the second reinforcement layer.

15. The cushioning structure of claim 1, wherein the cushioning structure is a cushioning structure for an article of clothing or athletic equipment.

16. The cushioning structure of claim 1, wherein the cushioning structure is a sole structure for an article of footwear, or is a component of a sole structure for an article of footwear.

17. A method for manufacturing a buffer structure, the method comprising:

The externally reinforced bladder is formed by the following steps:

assembling a stack comprising a first polymer sheet, a second polymer sheet, a first reinforcement layer, and a second reinforcement layer, wherein in the assembled stack, each polymer sheet comprises an inner surface and an opposing outer surface;

The first reinforcement layer is in contact with the outer surface of the first polymer sheet, the first reinforcement layer having a greater modulus than the first polymer sheet;

The second reinforcement layer is in contact with an outer surface of the second polymer sheet, the second reinforcement layer having a greater modulus than the second polymer sheet; and

The assembled stacked layers are bonded together into the externally reinforced bladder, wherein the externally reinforced bladder comprises

wherein in said externally reinforced bladder, said first reinforcement layer is bonded to said first polymer sheet only at said peripheral flange;

18. The method of claim 17, wherein the bonding step comprises thermal bonding by softening or melting the first polymer sheet, the second polymer sheet, or both the first polymer sheet and the second polymer sheet.

19. The method of claim 17, wherein the cushioning structure is a cushioning structure for an article of footwear, apparel, or athletic equipment.

20. A footwear article comprising:

an upper adapted to be secured about a wearer's foot; and

A sole structure connected to the upper, the sole structure comprising a cushioning structure, the cushioning structure comprising:

An externally reinforced bladder, the externally reinforced bladder comprising:

wherein the capsule comprises:

one or more interior volumes at which an interior surface of the first polymer sheet is spaced apart from an interior surface of the second polymer sheet to define the one or more interior volumes between the first polymer sheet and the second polymer sheet;

wherein in said bladder, said first reinforcement layer is bonded to said first polymer sheet only at said peripheral flange; and